Refastenable diapers and sheets therefor

Abstract

 A refastenable disposable diaper having a backsheet of low density polyethylene and polypropylene.

Description

[0001] This invention relates to disposable diapers (and backsheets and compositions for use therein) having normally tacky and pressure-sensitive adhesive tape closures and is particularly concerned with composite closures (i.e. closures made with more than one tape) that can be opened and refastened without destroying either the diaper or the tape.

[0002] The invention especially relates to a thermoplastic monolayer film suitable for use as a refastenable diaper backsheet comprising a blend of polyolefins particularly polypropylene and polyethylene.

[0003] At least as early as 1955 it had been suggested to use strips of normally tacky and pressure-sensitive adhesive tape to hold conventional cloth diapers on an infant; see, e.g. Chambers U.S. Pat. No. 2,714,889 and Ekberg U.S Pat. No. 3,221,738. A few years later, when disposable diapers became extremely popular, stips of pressure-sensitive adhesive tape were again employed as closures; see, e.g., Gellert U.S. Pat. No. 3,620,217.

[0004] A disposable diaper typically has a thin, flexible, stretchy low density polyethylene film cover, an absorbent filler on the inside of the cover, and a porous inner liner overlying the filler. Such a diaper is positioned at the crotch of an infant, the two ends of the diaper extending, respectively, toward the front and back. Adjacent edges of the diaper at each side are then either positioned next to each other or overlapped, a strip of pressure-sensitive adhesive tape being adhered to the cover at the border adjacent each of the two edges and holding the diaper closed. Because most pressure-­sensitive adhesives bond firmly to the thin polyethylene diaper cover, it is almost impossible to open the tape closure without destroying the tape and/or the diaper cover in the process.

[0005] After a tape closure has been opened, it is frequently discovered that the diaper has not been soiled and hence that there is no need to replace it. If the cover has not been torn, a second strip of tape can some­times be applied as a replacement closure, but this is often inconvenient. As a result, considerable work has been undertaken to develop a tape diaper closure that is not only capable of bonding firmly to the diaper cover, but is also capable of non-destructive removal and replacement. Closures of this type have generally involved a combination of two or more tapes, one of which remains permanently adhered to one edge of the diaper and is removably adhered to a so-called "target tape" mounted on the other edge of the diaper. Examples of such products are shown in Ness et al, U.S. Pat. No. 3,951,149, Milnamow U.S. Pat. No. 3,987,793, Feldman et al U.S. Pat. No. 3,999,546, and Richman et al U.S. Pat. No. 4,020,842.

[0006] The patents referred to in the preceding paragraph do not discuss the manner in which the closures are pre­pared. Typically in making such closures, the manufac­turers of diapers mount rolls of the appropriate tape in their equipment, combining them to form a composite strip of tape, the width of which is substantially the same as the length of the diaper closure to be fabricated. The composite roll is then severed at right angles to the edges of the composite strip at intervals corresponding to the width of the desired tape closure and adhered at an appropriate loacation along the border adjacent the sides of the diaper. Although this manufacturing process is effective, many relatively small manufacturers are unable to provide the machinery necessary to accomplish the superimposition of several rolls of tape. As a result, it is important for a tape supplier to provide the manu­facturers with a composite roll, made up of two or more specific tapes from which closures may readily be prepared.

[0007] A variety of diapers have been made with resealable tapes or refastenable disposable diapers. Representative are U.S. Patents 4,049,001, 4,055,181, 4,158,363, 4,227,530, 4,296,750, 4,345,597, and 4,369,786; European Patent Application 148,587; and West German Patent No. 3,419,623.

[0008] U.S. 4,330,888 discloses a disposable bib or napkin with an upper edge portion carrying a pressure-­sensitive adhesive capable of releasably adhering to the clothing or body of a user. British patents 1,320,628 and 1,342,115 disclose adhesive sheets or adhesive composite material which will releasably adhere to itself.

[0009] Additional diapers with tape fastening systems are described in U.S. 3,646,937, U.S. 3,848,594, U.S. 3,874,386, U.S. 3,951,149, U.S. 3,987,793, U.S. 3,999,546, U.S. 4,014,339, U.S. 4,014,340, U.S. 4,020,842, U.S. 4,041,949, U.S. 4,047,004, U.S. 4,194,507, U.S. 4,207,895, U.S. 4,209,016, U.S. 4,237,889, U.S. 4,573,986, and U.S. 4,578,071.

[0010] A wide variety of refastenable diapers have been constructed with varying degrees of success. One type of product has a one-piece pressure-­sensitive tape tab system which permits multiple fastening and refastening of the pressure-sensitive diaper tape tab to the embossed thermoplastic film used as the outside or backsheet of the diaper.

[0011] This invention includes a resin composition for making an embossed thermoplastic film backsheet which with suitable fastening tape can be fastened and refastened as many times as desired.

[0012] The present invention further provides a theromoplastic resin composition for making an embossed monolayer thermoplastic film which may be effectively utilized as the outside or backsheet of refastenable disposable diapers having a refastenable diaper backsheet film having improved tensile strength.

[0013] The invention also provides a thermoplastic resin composition suitable for making a refastenable backsheet which may be either blown film constructed or cast-film constructed.

[0014] The present invention provides a refastenable disposable diaper having a backsheet of thermoplastic film comprised of a blend of polypropylene and low density polyethylene. Linear low density polyethylene or linear medium density polyethylene may be used in whole or in part as the low density polyethylene.

[0015] An embossed monolayer thermoplastic film suitable for use as an outside sheet or backsheet of a refastenable disposable diaper preferably has a transverse direction (T.D.) tensile strength (stress) value at low elongations (<25%) between one pound and three pounds; T.D. tensile strength @ break values above two pounds; gloss @ 45 values (non-treated side) ≦ 8; slip C.O.F. (ccefficient of friction) values (non-treated side) between 0.3 and 0.9 and tape peel force value between one pound and two pounds at nominal film thicknesses (≦ 1.5 mils).

[0016] A refastenable diaper sheet can be made using either a blown-film or cast-film extrusion. Blown-film extrusion is preferred because films so made will be more balanced in the machine and transverse directions and have higher toughness values.

[0017] Non-refastenable embossed monolayer thermoplastic films used as the outside sheet or backsheet of a dis­posable diaper have been made largely of low density polyethylene (LDPE) resin blended with white pigments and slip additives as required to obtain the opacity (ash) and slip, coefficient of friction (C.O.F.) values needed. With a film thickness of about 1.5 mils, such resin provides a suitable refastenable diaper backsheet. At film thicknesses of less than about 1.5 mils, films of such resins don't have insufficient transverse direction (T.D.) tensile strength (stress) values at low elongations (≦25%) and consequently the film tends to tear or excessively distort as a pressure-sensitive diaper tab is peeled off. To boost the low T.D. tensile strength (stress) values, polyolefins such as high density poly­ethylene (HDPE) or medium density linear polyethylene (LMDPE) are added to the resin blend for making the film. Larger amounts of each (percent by weight) are required to obtain the desired stress value as nominal film thickness decreases.

[0018] Although these polyolefin blends may produce thermoplastic films of the desired T.D. tensile strength (stress) at low elongations, the film may have lowered tape adhesion, lowered drop dart impact (increased splittiness) and less than desired slip C.O.F.

[0019] At nominal film thickneses of 1.0-1.5 mils, conventional LDPE film extrusion equipment is detri­mentally influenced by the high head pressure and torque requirements of the high loadings (percent by weight) of HDPE or LMDPE required to obtain the T.D. tensile strength (stress) values needed for refastenability.

[0020] It has been discovered that blending from three weight percent to 30 weight percent polypropylene with LDPE, LLDPE, LMDPE, or mixtures of any two of the three resins, monolayer films can be produced which have the desired refastenability characteristic, i.e. increased T.D. tensile strength (stress) at elongations and increased tape adhesion without significant degradation of other film physical properties. The preferred blend contain 5-25 Weight percent polyporpylene is preferred, with 10-20 weight percent polypropylene being most preferred.

[0021] For monolayer films, the gauge of the film should be 1.0 to 1.5 mils.

[0022] Some examples of monolayer thermoplastic films suitable for refastenable backsheets of disposable diapers are set forth in Table I.

[0023] Coextruded or multilayer films are also suitable for use as a refastenable diaper backsheet. Such films should have a core layer of 50-100 percent polypropylene. The values for the monolayer films are applicable to the coating layers of coextruded films.

[0024] The core of a a 1.0 mil coextruded film having 0.2 mil outer oatings is illustrated in Table II.

[0025] In embossed monolayer films containing poly­propylene in combination with linear low density poly­ethylene and/or linear medium density polyethylene, the advantages of each of the resins is obtained. High stress and high tape adhesion qualities of polypropylene are obtained and the high values and high tensile strength values of the linear polyethylenes are obtained, thereby providing a film with significantly better overall physical properties than those customarily used in diaper backsheets. Stress at low elongations (≦25 percent) and tape adhesion are also similarly improved in coextruded films containing polypropylene.

[0026] In Table III, a comparison is shown between LDPE film and films of various blends. It is readily seen that films containing polypropylene have increased adhesion values and increased T.D. stress @ 10%.

[0027] In Table IV, comparisons between similar films with and without polypropylene are illustrated. It is readily seen that films containing polypropylene have increased T.D. tensile strength (stress) at low elongations (≦25 percent) and increased tape adhesion.

[0028] A disposable diaper comprises in general, a facing sheet defining a diaper inside surface for direction toward an infant, a moisture-impervious backsheet sub­stantially coextensive with the facing sheet and defining a diaper outside surface, an absorbent panel positioned between the facing sheet and the backsheet, and an adhe­sive tab fastener means. On a refastenable or releasable tape closure, the tape or tab has a free end and a fixed end attached to the diaper. The free end of the tab has an adhesive which is adapted to be releasably affixed to the backsheet.

[0029] Refastenable diapers come in a variety of detailed constructions and releasable tapes. An example of such a diaper is illustrated in U.S. 4,330,888.

[0030] The present invention provides a unique backsheet for such a refastenable disposable diaper.

[0031] A preferred diaper backsheet is constructed of a resin blend comprising by weight percent, about 7 percent polypropylene, about 86 percent low density polyethylene and about 7 percent white concentrate.

[0032] A most preferred backsheet is constructed of a resin blend comprising by weight percent, about 12 percent polypropylene, about 83 percent low density polyethylene and about 5 percent white concentrate.

[0033] It can readily be appreciated that the instant invention can be incorporated in a variety of diaper constructions and releasable tape constructions. It is essential though that the diaper backsheet comprise or be made of sufficient polypropylene as to provide the desired strength and refastenability feature.

[0034] The foregoing disclosure and description of the invention is illustrative and explanatory thereof and various changes in the illustrated film or diaper con­struction may be made without departing from the scope of the invention.

Claims

1. A refastenable disposable diaper comprising a facing sheet, a backsheet, an absorbent panel positioned between said facing sheet and said backsheet and an adhesive tab fastener means attached to said back sheet, said backsheet being characterized by comprising a resin blend consisting essentially of polypropylene and a low density polyethylene in which from 3 to 30 weight percent of the resin blend is polypropylene.

2. A diaper as claimed in claim 1 in which the low density polyethylene is LDPE, LLDPE, LMDPE or a mixture of any two of such low density polyethylenes.

3. A diaper as claimed in claim 1 or claim 2 in which the polypropylene comprises 5 to 25 weight percent of the resin blend, preferably 10 to 20 weight percent of the resin blend.

4. A diaper as claimed in any one of claims 1 to 3 in which the backsheet is a monolayer film having a gauge of 1.0 to 1.5 mils.

5. A diaper as claimed in any one of claims 1 to 4 in which said backsheet has a transverse direction tensile strength value at 10 percent elongation of at least 515 grams and a 120° tab adhesion value of at least 380 grams.

6. A diaper as claimed in claim 5 in which the backsheet is a coextruded multilayer film comprising (a) a polypropylene inner core of 50 to 100 percent polypropylene, and (b) coating layers each composed of a resin blend of polypropylene and a low density polyethylene in which from 3 to 30 weight percent of the resin blend is polypropylene.

7. A diaper as claimed in claim 1 or claim 2 in which the backsheet is an embossed monolayer blown film having a nominal thickness of 1.0 to 1.5 mils made from a resin blend of low density polyethylene and polypropylene, the polypropylene constituting 5 to 25 weight percent of the blend.

8. A backsheet for refastenable disposable diapers consisting essentially of a blend of a low density polyethylene resin, a polypropylene resin, and a colour pigment, 3 to 30 weight percent of the resins in the blend being the polypropylene, said backsheet having a transverse direction tensile strength value at 10 percent elongation of at least 515 grams and a 120° tape adhesion value of at least 380 grams.

9. A backsheet as claimed in claim 8 in whch the low density polyethylene is LDPE, LLDPE, LMDPE, or a mixture of any two of such low density polyethylene resins.

10. A backsheet as claimed in claim 9 composed of from 10 to 20 weight percent polypropylene, from 20 to 40 weight percent LMDPE, from 45 to 65 weight percent LDPE, and up to 5 percent by weight of opacifying pigment.

11. The use of a blend of polypropylene and low density polyethylene (a) in providing a resin composition suitable for the manufacture of a diaper backsheet, or (b) in the production of a diaper backsheet, or (c) in the production of a diaper.